Wireless MEMS sensing device

ABSTRACT

A sensor component that may be used in conjunction with a filter module may include a plurality of sensor packages. The latter, in turn, may incorporate one or more micro-electromechanical systems (MEMS) sensors to measure various characteristics of fluid flow and filtration. A single sensor component may be adapted to measure the pressure, temperature, flow rate, differential pressure, conductivity, viscosity, pH level, etc. of the fluid at an upstream and a downstream location. Sensor measurements may be obtained continuously in order to monitor and indicate fluid conditions, including the use of a warning mechanism to indicate an out-of-range condition when the measurements fall outside of pre-set limits. Depending on the application and the fluid being filtered, data, including measurement data, may be transmitted through electrical connections or wirelessly. In wireless configurations, a sleep-mode may be included to maximize the life of local power supplies.

RELATED APPLICATION DATA

This is a continuation of application Ser. No. 10/281,834, filed Oct.28, 2002, now U.S. Pat. No. ______, and is related to application Ser.No. 11/006,137, filed Dec. 7, 2004, which is a continuation ofapplication Ser. No. 10/281,835, filed Oct. 28, 2002, now U.S. Pat. No.6,852,216; to application Ser. No. 11/028,978, filed Jan. 4, 2005, whichis a continuation of application Ser. No. 10/818,248, filed Apr. 5,2004, now U.S. Pat. No. 6,855,249, which is a continuation of Ser. No.10/259,905, filed Sep. 27, 2002, now U.S. Pat. No. 6,736,980, which is adivision of application Ser. No. 09/721,499, filed Nov. 22, 2000, nowU.S. Pat. No. 6,471,853; and to application Ser. No. 10/903,727, filedJul. 30, 2004, now U.S. Pat. No. ______, which is a continuation ofapplication Ser. No. 10/281,692, filed Oct. 28, 2002, now U.S. Pat. No.6,823,718.

FIELD OF INVENTION

The present invention is directed to filtration systems incorporatingmicro-electromechanical systems (MEMS) to provide flow and filtrationcharacteristic data.

BACKGROUND

Filter modules have been used in a variety of applications and fluidicenvironments. When in service, it is often desirable to sense andmeasure various fluid flow and filter performance characteristics inorder to determine whether a filter element within the filter module isperforming within application specifications, and whether a filterelement must be replaced or reconditioned before continuing operation.

In typical filter modules, a filter element is encased within a filterbody, or casing (e.g., a filter bowl), and between inlet and outlet endcaps. A filter manifold(s) may be attached to the filter body to feedunfiltered medium to the upstream side of the filter element (e.g.,where the filter element is cylindrical, the outside of the filterelement). As the medium passes to the downstream side of the filterelement through the membrane material, contaminants are removed from themedium. Filtered medium is then collected from the downstream side ofthe filter element (e.g., where the filter element is cylindrical, theinside of the filter element).

During the filter element's service life, an increasing amount ofremoved contaminant will collect on one side of the filter element in aphenomenon known as fouling. Fouling causes the pressure differencebetween the upstream and downstream sides of the filter element toincrease, and thereby lowers the filtration efficiency of the filterelement. If the differential pressure exceeds a certain value that isdependent upon the filter element material and design, the filterelement may be damaged. Additionally, at high differential pressures,particle breakthrough (i.e., contaminant particles passing through thepores in the filter element) may occur.

In prior modules, the filter head may have contained conventionalpressure transducers, magnetic type differential pressure sensors,virtual pressure switches, and temperature detectors to measurecharacteristics of fluid flow and filter performance. These componentsare used to sense the differential pressure across the filter element todetermine whether the filter element is sufficiently clogged withcontaminant removed from the fluid flow to require replacement. Thesepressure sensors are generally binary in nature, i.e., they eitherindicate that the filter element needs to be replaced (e.g., by causinga part to pop up out of the exterior of the filter head) or that it isstill useable.

Typically, traditional differential pressure indicators (e.g., springand piston designs) contain a multiplicity of discrete, macro-scale,mechanical parts and/or components, which makes them more prone tofailure. As an example, a thermal lockout mechanism is typically used toprevent false indications during cold-start conditions. In existingdesigns, the thermal lockout mechanism uses the thermal expansionqualities of BI-metal strips to keep the differential pressure indicatorfrom actuating until a pre-set temperature is reached. However, falseindications are received when mechanical failures occur within thelockout mechanism.

The use of the pressure-sensing components used in traditional filtermodules is also often a significant design constraint in weight- andsize-sensitive applications, e.g., aircraft filtration systems.Moreover, traditional filter modules offer no real-time means forpredicting when a filter element will need to be replaced. In addition,traditional filter modules disturb or alter fluid flow by requiring thatsensing components be inserted into the stream of flow, creatingturbulence. Also, prior sensors are designed to indicate an out-of-rangecondition when the value of a measured property falls outside of pre-setlimits. As such, continuous measurement and real-time monitoring andindication may not be available with such designs.

Moreover, traditionally, separate devices have typically been used tomeasure different properties (e.g., temperature and pressure), thusincreasing the size and cost of the overall system. Similarly, atpresent, filter or fluid power manifolds that have separate upstreamcircuits but share a common downstream passage require the use ofseparate devices to measure, e.g., differential pressure, across eachfilter element (or any device or component that provides a measurablepressure drop). This also holds true for filter or fluid power manifoldsthat have separate downstream circuits, but share a common upstreampassage. As before, the use of separate individual devices is generallydisadvantageous as it leads to increased cost, weight, design envelopesize, and reduced reliability.

In recent years, attempts have been made to overcome the above-mentionedshortcomings by using Micro-Electro-Mechanical Systems (MEMS) devices inconjunction with filter modules. MEMS devices comprise semiconductorchips which include microfabricated mechanical systems on the chip. Moregenerally, MEMS are directed to the integration of mechanical elements,sensors, actuators, and electronics on a common substrate through theutilization of microfabrication technology. While the electronics arefabricated using integrated circuit (IC) process sequences, themicromechanical components are fabricated using compatiblemicromachining processes that selectively etch away parts of a siliconwafer, e.g., or add new structural layers (e.g., by deposition), to formthe mechanical and electromechanical devices. In this way, MEMSrepresents a complete systems-on-a-chip, free of discrete, macro-scale,moving mechanical parts. In short, in MEMS devices, the microelectronicintegrated circuits provide the decision-making capability which, whencombined with MEMS sensors, actuators, etc., allow Microsystems tosense, provide feedback to/from, and control the environment.

Thus, commonly-assigned U.S. application Ser. No. 09/721,499, filed Nov.22, 2000, now U.S. Pat. No. 6,471,853, is directed to a filter modulethat incorporates MEMS sensors to measure various characteristics offluid flow and filtration, including the temperature, flow rate,pressure, etc. of the fluid. One or more MEMS sensors may beincorporated into a sensor package which, in turn, is included in asensor component. The latter, which typically may include a processor,conductor pins, etc. for data communication, is coupled to a sensor portof a manifold in such a way as to allow contact between the fluid and atleast one surface of the sensor(s).

As shown in FIGS. 1A and 1B, a filter module containing a MEMS sensorcomponent of the type described in the above-mentioned patentapplication may include a filter body (e.g., a filter bowl) 1, a filterelement 2, and a filter manifold 3. The filter manifold 3 may have oneor more sensor ports 4 in which one or more MEMS sensor components 5 maybe mounted. The filter manifold 3 may have one or more inlet fluid flowcavities 6 and one or more outlet fluid flow cavities 7. The sensorports 4 may extend through the housing 8 of the filter manifold 3. Sealsmay be used to ensure that the interface between each sensor port 4 andthe corresponding sensor component 5 is made fluid-tight.

The filter element 2 may have an end cap 9 attached to one end (the deadend). In general, the shape and location of the inlet fluid flow cavity6 and the outlet fluid flow cavity 7 may depend upon a number offactors, including the desired flow characteristics of the unfiltered orfiltered fluid, the size and shape of the filter element 2 and filterbody 1, the fluid being filtered, and the like. Each sensor component 5includes a sensor package 10 which contains one or more MEMS sensors. Asshown in FIG. 1B, the sensor ports 4 and the sensor components 5 areconfigured such that, when in place, each sensor package 10 is flushwith the stream of fluid flow (e.g., flush with the inner surface ofinlet cavity 6 and outlet cavity 7).

In order to measure the differential pressure between two locations offluid flow (e.g., across a filter element 2) using MEMS sensorcomponents of the type described above, at least two such sensorcomponents must be used. More specifically, a first MEMS sensorcomponent 5 having at least one pressure sensor is deployed at anupstream location, e.g., within a port 4 in an inlet cavity 6, and asecond MEMS sensor component 5 having at least one pressure sensor isdeployed at a downstream location, e.g., within a port 4 in an outletcavity 7. Respective pressure readings from the first and second sensorcomponents are communicated to a processor or similar device throughelectrical conductors, and a differential pressure across the membraneof the filter element 2 is calculated based on the difference betweenthe first and second sensor component readings.

MEMS sensor components of the type described above have thus improvedupon conventional modules and sensors by eliminating macro-scalemechanical parts, addressing weight and size concerns, allowingreal-time monitoring, and providing a sensor package that can be placedflush with the stream of flow, thus avoiding interference with fluidflow. Nevertheless, in light of the high cost of retrofittable sensors(e.g., differential pressure sensors) and the difficulties associatedwith wiring such sensors to a “communications bus”, there is a need forlow-cost, lower-weight, reliable, non-mechanical sensing devices thatmay be retrofittable, capable of integrating one or more differentialpressure sensors, and capable of wirelessly communicating sensing- andmeasurement-related data.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B depict a typical filter module having a manifold whichis configured to receive one or more sensor components within sensorports thereof;

FIG. 2 shows a sensor component according to an embodiment of thepresent invention;

FIG. 3 is a bottom view of the embodiment shown in FIG. 2;

FIG. 4 shows a cross-sectional view through segment A-A of theembodiment shown in FIG. 3;

FIG. 5 shows a top view of the embodiment shown in FIG. 2;

FIG. 6 shows a side view of the embodiment shown in FIG. 2;

FIG. 7 is an illustration of an alternative embodiment of the presentinvention;

FIG. 8 is a bottom view of the embodiment shown in FIG. 7;

FIG. 9 shows a cross-sectional view through line A-A of the embodimentshown in FIG. 8;

FIG. 10 shows a cross-sectional view through line B-B of the embodimentshown in FIG. 8;

FIG. 11 shows an attachment configuration for use with an embodiment ofthe present invention;

FIG. 12 shows an alternative embodiment of the present invention;

FIG. 13 depicts a schematic of a hydraulic system using a sensorcomponent according to an embodiment of the present invention;

FIG. 14 shows an alternative embodiment of the present invention;

FIG. 15 shows a top view of the embodiment depicted in FIG. 14;

FIG. 16 shows a cross-sectional view through segment A-A of theembodiment shown in FIG. 15;

FIG. 17 is an illustration of an alternative embodiment of the presentinvention;

FIG. 18 shows an embodiment of a filter element bowl and signal receiverof the embodiment shown in FIG. 17;

FIG. 19 is an exploded view of an end cap of the embodiment shown inFIG. 17; and

FIG. 20 is an illustration of a signal receiver assembly of theembodiment shown in FIG. 18.

DETAILED DESCRIPTION

Embodiments of the present invention are directed to sensor componentsin which various MEMS sensors for measuring pressure, differentialpressure, flow rate, temperature, pH level, viscosity, and/or moisturecontent of the fluid flow may be used. Multiple MEMS sensors may bearranged on a single chip to form a sensor package, and multiple sensorpackages may be included in a single, unitary sensor component. The MEMSsensors may output real-time measurements or related data, thus allowingreal time continuous monitoring of the fluid system. The measurements ordata may be interpreted to predict when failure of the filter elementwill occur or to determine whether replacement of the filter element isnecessary. In particular embodiments, MEMS sensor data may be used todetect the occurrence of undesirable events such as particlebreakthrough or cavitation.

In addition to allowing real time continuous monitoring (as opposed tomerely providing an indication at pre-set values), the present inventionimproves reliability by reducing the number of macro-scale mechanicalcomponents and/or moving parts that are typically used in traditionalsystems, as well as by allowing redundancy of sensor packages and/or ofsensors within a given sensor package. Moreover, by including multipleMEMS sensors on a sensor package, the present invention eliminates theneed for separate devices to measure temperature, pressure, differentialpressure, etc. This, in turn, reduces costs, as well as system weightand envelope size.

In some embodiments, a single sensor component may contain multiplepressure sensors which are configured in such a way as to allowdetermination of a differential pressure without the need to include anadditional sensor component. Thus, the inclusion of multiple sensorpackages in a single sensor component allows installation, orretro-fitting, in applications where only one port is available andtraditional devices and methods would require two separate sensor portsand assemblies (e.g., measuring differential pressure with a singlesensor component placed into a single port, as opposed to placing twoseparate sensor assemblies into two separate ports).

Embodiments of the present invention are also directed to single-bodysensor components (e.g., single-body differential pressure devices) thatmay be used in systems having multiple separate upstream circuits thatshare a common downstream passage or, vice versa, where multipleseparate downstream circuits share a common upstream passage. In oneembodiment, the present invention also provides a MEMS sensor componenthaving a wireless data-communication capability.

FIG. 2 shows a sensor component 500 according to an embodiment of thepresent invention. As shown in FIGS. 3-6, the sensor component 500 maygenerally have a cylindrical configuration. In a preferred embodiment,the sensor component 500 includes at least a first MEMS sensor package522 and a second MEMS sensor package 524, wherein each sensor packagecontains one or more MEMS sensors, including sensors for measuringpressure, temperature, differential pressure, and flow rate. In theembodiment of FIG. 4, a bottom view of which is shown in FIG. 3, a thirdsensor package 530 may be included, with MEMS sensors for measuringviscosity, pH level/acidity, conductivity, free water content,lubricity, oxidation reduction potential (ORP), etc. of a given fluid.

In a preferred embodiment, at least one of the sensor packages (e.g.,the first sensor package 522) is exposed directly to the upstream fluid,i.e., the fluid that is transmitted to the inlet side of the filterelement. Thus, as shown in FIG. 4, when placed into a sensor port 547, afront face of the sensor package is flush with the interior surface 517of the filter manifold 516 (or of the fluid flow cavity, or otherstructure housing the sensor component) in such a way as to be incontact with the fluid as it flows by.

A second sensor package, however, might not be flush with the stream offluid flow. Rather, as depicted in FIG. 4, the second sensor package524, e.g., is isolated from the upstream fluid via a plug 528 that isinserted at one end of the sensor component 500. The second sensorpackage 524 is arranged such that it can measure properties of thedownstream fluid (e.g., the fluid that is transmitted from the outletside of the filter element) through an aperture 542 (see FIG. 6) withinthe casing 515 of the sensor component 500, and a channel 526 (see FIG.4) that provides an opening through the manifold 516. Thus, downstreamfluid measurement may be obtained by porting the downstream fluid to thesecond sensor package 524. In an alternative embodiment, downstreamfluid conditions may be monitored without direct contact between thefluid and the sensor package 524 by using, e.g., a pitot-tube-typearrangement in conjunction with channel 526 and aperture 542. Inaddition, an isolation seal 520 may be used to isolate upstream anddownstream pressures.

In embodiments of the present invention, data collected using themultiplicity of sensors and/or sensor packages may be processed and/ortransmitted through the use of electrical conductors and data-processingdevices. For example, the embodiment shown in FIG. 4 includes electricalconductors 518 for communication of measurement data to a processor 512.The processor 512, in turn, may be connected to conductive pins 550 ofan electrical connector signal interface 510 in such a way as to allowtransmission of data from the sensor component 500 (to, e.g., a separatedata processing device). In other embodiments discussed below, datatransmission may be achieved wirelessly.

Advantageously, using the data collection/transmission/processingcapabilities described herein, embodiments of the present inventionallow for measurement of differential pressure and similar parametersusing a single MEMS sensor component by including multiple sensorpackages within the same sensor component. This is especially desirablein applications (e.g., retrofitting/updating older systems) where onlyone sensor-component port, rather than two, is available for measuringdifferential pressure and other such parameters. In addition, incontrast to existing designs, where an indication is provided only whenpre-set parameter values have been reached, embodiments of the presentinvention allow continuous real-time monitoring of the fluid system.

Moreover, embodiments of the present invention achieve improvedreliability by allowing the use of redundant sensor packages, as well asredundant sensors in each sensor package. Also, the sensors may betemperature compensated to ensure accuracy over the entire missionrange. In addition, given their relatively small mass, the MEMS sensorpackages are inherently tolerant of extreme vibrational environments.

In an alternative embodiment, shown in FIGS. 7-10, the sensor component500 comprises a warning mechanism 610 at an end opposite the sensorpackages 522,524. The warning mechanism 610 may include a visual warninglight, an audible alarm, etc. configured to indicate an out-of-rangecondition of the fluid. Typically, the warning mechanism 610 will bebattery operated, utilizing a replaceable battery 630 as depicted inFIG. 9. In addition, the sensor component 500 may include a transparentdust cover 620 to protect the warning mechanism 610, especially when thewarning mechanism 610 is a visual warning light.

The embodiment shown in FIGS. 7-10 includes the first and second sensorpackages, 522, 524, as well as a third sensor package 530. Morespecifically, FIG. 10 shows a cross-sectional view of the sensorcomponent through line A-A of FIG. 8, and FIG. 10 shows across-sectional view of the sensor component through line B-B of FIG. 8.In FIG. 9, the second sensor package 524 is shown with a connection tothe processor 512 via electrical conductors 518. FIG. 10, on the otherhand, depicts the first sensor package 522, and the third sensor package530.

As shown in FIG. 4, the sensor component 500 may be held in place withinthe sensor port 517 by a housing seal 514. Alternatively, the variousembodiments of the sensor component 500 may be threaded, or may includea flange 680 that is perpendicular to the longitudinal axis of thesensor component 500 and which protrudes from the periphery of thesensor component (see FIG. 11). The flange 680 is configured to besecured to the filter manifold 516 with bolts or other similar means,thus holding the sensor component in place.

FIG. 12 shows yet another alternative embodiment of the sensor component500. Here, a warning mechanism is contained within the casing 515 of thesensor component 500. The casing 515, in turn, includes circumferentialholes 693 through the periphery thereof, such that a visual warninglight can be seen through the holes 693. As such, in this embodiment, avisual out-of-range indication is provided through the holes 693 ratherthan through a transparent cover (e.g., transparent dust cover 620)placed at one end of the sensor component 500.

FIGS. 13-16 show an alternative embodiment of the present invention forapplications requiring data collection from more than two points withina given system. More specifically, FIG. 13 is a schematic diagram of ahydraulic system wherein three hydraulic components (e.g., a filter orother component across which a measurable pressure drop exists), eachwith a separate upstream circuit, are arranged so as to have a commondownstream passage. Traditionally, differential pressure measurementsacross each of the components HC1, HC2, HC3 would require two separatepressure sensors, one of which would be placed upstream, and the other,downstream, of the component. As such, for the system shown in FIG. 13,at least four separate pressure sensors (i.e., one at each upstreamcircuit, and one at the common downstream passage) would have to beused.

Taking advantage of the principles discussed herein, however,embodiments of the present invention allow for the use of fewer sensingdevices. For example, only three sensor components of the type discussedin connection with FIGS. 2-12 need be used to calculate differentialpressures across all of the components HC1, HC2, and HC3. This isespecially true when the components HC1, HC2, and HC3 share neither acommon upstream passage nor a common downstream passage.

When either a common upstream passage or a common downstream passageexists, however, an alternative embodiment of the present inventionenables calculation of all of the differential pressures using a singleMEMS sensor component (i.e., a single-body differential pressure sensingdevice). Thus, with reference to the schematic of FIG. 13, a singlesensor component having four sensor packages is used, wherein threepressure sensor packages are used to monitor the three separate upstreampressures of the system, and one pressure sensor package is used tomonitor the common downstream pressure, thus allowing for a smaller,lighter, and more reliable hydraulic system.

FIGS. 14-16 show a sensor component 700 that is adapted to detectdifferential pressures across two separate hydraulic components thatshare either an upstream or a downstream passage. This arrangement wouldutilize three sensor packages, each having at least one MEMS pressuresensor. Accordingly, sensor component 700 includes three sensor-packagereceptacles 781, 783, 785, two of which may receive sensor packages formonitoring pressures in the two separate (e.g., upstream) circuits, andthe third may receive a sensor package for monitoring pressure at thecommon (e.g., downstream) passage.

It is noted that each of the sensor packages mentioned above may includeadditional sensors, e.g., one or more MEMS temperature sensors inaddition to the at least one MEMS pressure sensor. Also, as shown by wayof example in FIG. 14, the sensor component 700 may optionally include,at a bottom face 791 thereof, a separate sensor package 790 for flowmeasurement. When this is the case, the sensor component 700 alsoincludes an electrical lead passage 787 which provides a conduit leadingaway from the fluid flow sensor package 790.

As shown in FIGS. 14 and 16, the receptacles 781,783,785 are in flowcommunication with separate pressure-port apertures 742 a,742 b,742 c,respectively. Thus, as discussed previously in connection with theembodiment shown in FIGS. 4 and 6, each of the sensor packages containedin the receptacles 781,783,785 may be configured to measure propertiesof the fluid at a different location by porting the fluid to a sensorpackage through a respective pressure-port aperture 742 a,742 b,742 c.This may be done, for example, by using channels that are similar tochannel 526 shown in FIG. 4. In this regard, an isolation seal 720 a,such as an O-ring, may be used to isolate system pressure betweenpressure-port apertures 742 a and 742 b. Similarly, an isolation seal720 b may be used to isolate system pressure between pressure-portapertures 742 b and 742 c. In addition, the sensor component 700 mayinclude a third isolation seal 714 to isolate the sensor component fromthe atmosphere (see, e.g., housing seal 514 in FIG. 4).

Data collected using the multiplicity of sensors and/or sensor packagesmay be processed and/or transmitted through the use of electricalconductors and data-processing devices. To this end, sensor component700 includes an electrical housing 715 which may include electricalconductors, one or more processors, and/or conductive pins (within anelectrical connector 710) which may be configured to allow transmissionof data to/from a data processing device.

In addition, the sensor component 700 may include a visual warninglight, an audible alarm, or other warning mechanism that is configuredto indicate an out-of-range condition of the fluid for each of thehydraulic components being monitored. Moreover, similar to flange 680shown in FIG. 11, sensor component 700 may include a mounting flange 780that is configured to be secured to a filter manifold (not shown), thusholding the sensor component in place.

FIGS. 17-20 show an alternative embodiment, wherein measurement data maybe wirelessly transmitted to a remote signal receiver 852 (i.e., asignal receiver that is not electrically connected to the sensorcomponent). A filter element 2, having an end cap 9 (see FIGS. 1A and1B), is normally housed in a bowl, or casing, 850. In this embodiment, asensor component 860 may be placed in a port 868, which may be an axialopening through the end cap 9. The sensor component 860 may generally beof the types discussed in connection with FIGS. 2-16, where a pluralityof sensor packages, each having one or more MEMS sensors, are includedwithin a single sensor component. Thus, although FIGS. 17-20 depict awireless differential pressure device, wherein a single sensor component860 is configured to measure a differential pressure using a pluralityof sensor packages and MEMS pressure sensors that are in communicationwith the unfiltered and filtered fluids, it will nevertheless beunderstood that such depiction is by way of example only. That is, thefeatures of the invention discussed herein may be applied to sensorcomponents that enable measurement of properties other than (or inaddition to) the fluid's upstream and downstream pressures, as well asto configurations in which redundant sensors and/or sensor packages maybe used.

As shown in FIG. 19, the sensor component 860 includes asensor-component housing 880 which, in a preferred embodiment, isadapted to be snapped into the port 868. In this way, an embodiment ofthe invention provides a re-usable sensor component for use with afilter element 2 which, itself, may be a throw-away component. Thesensor component 860 may include a sealing member 870, such as, forexample, an O-ring, so as to provide a fluid-tight interface between thesensor port 868 and the housing 880, thus preventing any flow bypassthrough the port 868.

The sensor component 860 may be retained in the port 868 using one ormore retaining braces 862, 864, 866, which may be overlapped. In oneembodiment, each of the retaining braces 862, 864, 866 includestransverse apertures 863, 865, 867, respectively, which come intoalignment with end cap apertures 869. The end cap 9 and the brace(s) arethen held together by passing connection means 861, such as pins, orsnap members, through the end cap apertures 869 and the transverseapertures 863 (865, 867).

As has been discussed in connection with embodiments describedpreviously, the sensor component 860 may also include hardware,including one or more processors, electronics, etc. for processingmeasurement data prior to transmission. In addition, the sensorcomponent 860 may include a power supply 890. In a preferred embodiment,the power supply 890 includes a battery, which may be rechargeable, andwhich provides the sensor component 860 with stand-alone, wireless,functioning capabilities.

FIGS. 18 and 20 show an embodiment of the casing 850 and remote signalreceiver 852 of the present invention. The casing, or bowl, has a topend 858 and a bottom end 851, wherein the latter may be proximate theend of the filter element 2 which has the end cap 9 mounted thereon(see, e.g., FIG. 17). The signal receiver 852 includes a receiverhousing 853, as well as a power supply and hardware (e.g., processor,electronics, etc.) 857 that are encased within the housing 853 and maybe locked in place using an insert 856. The insert 856 may be, e.g., anylon thread-lock insert. As with the sensor component 860, the powersupply of the signal receiver 852 may include a rechargeable battery,thereby providing a stand-alone, self-powered signal receiving unit. Thesignal receiver 852 may be coupled to the bottom end 851 of the casing850, e.g., by providing mutually-mating threaded surfaces. In apreferred embodiment, the signal receiver 852 also includes a warningmechanism 854, such as a visual (LED) indicator.

In practice, the filter element 2 having a sensor component 860 in anend cap 9 thereof is housed by the casing 850 having a signal receiver852 in a bottom end 851 thereof. The sensor component includes sensorpackages that are in communication with the unfiltered and filteredfluids. Thus, as fluid flows through the filter, the sensor component860 determines a differential pressure across the filter element 2. Inone embodiment, the measurement data is then transmitted, wirelessly, tothe signal receiver 852, when a predetermined differential pressure isreached. In another embodiment, data is wirelessly transmitted inpredetermined intervals, or continuously in real time.

Depending on the type and properties of the fluid being filtered, thedata transmission between the sensor component 860 and the signalreceiver 852 may be achieved through RF signals, ultrasonically, orthrough other means of wireless communication. Once received by thesignal receiver 852, the data may be either processed locally ortransmitted to a central computer or data processing device, asdiscussed with respect to the embodiments of FIGS. 2-16. In addition,the sensor component 860 may comprise a warning mechanism 854, such as avisual warning light, an audible alarm, or similar mechanism that isconfigured to indicate an out-of-range condition of the fluid (e.g.,when a pre-set level is reached). Thus, in various applications, acondition triggering the warning mechanism 854 may be based onmeasurement data transmitted to the signal receiver 852 relating topressure, temperature, flow rate, differential pressure, and/or otherfluid or filtration characteristics.

In one embodiment, the invention may include a sleep-mode feature,wherein the MEMS sensors of the sensor component 860, as well as thesignal receiver 852, are configured to remain in an unactuated state inthe absence of fluid flow. Once fluid flow has been initiated, thesensors become actuated, so that measurement data can now be taken. Inaddition, the signal receiver 852 will become actuated upon receipt ofmeasurement data. When in the sleep-mode, the sensor component's powersupply is configured to utilize minute amounts of current, e.g., on theorder of micro-amperes. As such, once activated, the power supply willsustain the sensor component as a self-powered unit for upwards of 6000hours. Similarly, once activated, the signal receiver 852 will remainself-sustaining for upwards of 3000 hours. As noted before, the sensorcomponent 860 and the signal receiver 852 may be removed or replacedwhen the filter element 2 is replaced with a new filter element.

While the description above refers to particular embodiments of thepresent invention, it will be understood that many modifications may bemade without departing from the spirit thereof. The accompanying claimsare intended to cover such modifications as would fall within the truescope and spirit of the present invention.

The presently disclosed embodiments are, therefore, to be considered inall respects as illustrative and not restrictive, the scope of theinvention being indicated by the appended claims rather than theforegoing description. All changes that come within the meaning, andrange of equivalency, of the claims are intended to be embraced therein.

1. A filtration monitoring system comprising: a filter module includinga filter element having an end cap at an end thereof, said filterelement receiving a fluid in an unfiltered state at an inlet side andproducing said fluid in a filtered state at an outlet side; asingle-body sensor component coupled to said end cap, said sensorcomponent having a single housing and at least a first sensor packageand a second sensor package disposed within said housing, each saidsensor package including a micro-electromechanical systems (MEMS)sensor, and each said sensor package being configured to measure atleast one member selected from the group consisting of temperature,pressure, and flow rate, wherein said filter element, said end cap, andsaid sensor component are adapted to be housed within a casing; atransmitter coupled to said sensor component, said transmitter beingconfigured to wirelessly transmit measurement data to a remote signalreceiver; and a data-processing device configured to receive data fromsaid signal receiver.
 2. The monitoring system of claim 1, wherein saidfirst sensor package is adapted to be in communication with saidunfiltered fluid upstream of said filter element and said second sensorpackage is adapted to be in communication with said filtered fluiddownstream of said filter element.
 3. The monitoring system of claim 2,wherein a differential pressure is calculated based on a pressuremeasurement taken by said first sensor package for the unfiltered fluidand a pressure measurement taken by said second sensor package for thefiltered fluid.
 4. The monitoring system of claim 3, wherein thedata-processing device is configured to calculate said differentialpressure.
 5. The monitoring system of claim 1, wherein each said sensorpackage includes a MEMS pressure sensor.
 6. The monitoring system ofclaim 1, wherein said sensor component further includes a processor. 7.The monitoring system of claim 6, wherein each of said first and secondsensor packages is configured to communicate its respective measurementsto said processor.
 8. The monitoring system of claim 1, wherein saidmeasurement data are transmitted to said signal receiver as RF signals.9. The monitoring system of claim 1, wherein said casing includes topand bottom ends and said signal receiver is coupled to the bottom end ofsaid casing.
 10. The monitoring system of claim 9, wherein the signalreceiver is threadably coupled to said bottom end.
 11. The monitoringsystem of claim 1, said signal receiver further including a warningmechanism configured to indicate an out-of-range condition of saidfluid.
 12. The monitoring system of claim 11, wherein said condition isdetermined based on measurement of one or more of said fluid's pressure,temperature, flow rate, and differential pressure, and said warningmechanism includes a visual indicator.
 13. The monitoring system ofclaim 1, further including a sleep-mode feature, wherein said first andsecond sensor packages and said signal receiver are configured to remainin an unactuated state in the absence of fluid flow, said first andsecond sensor packages becoming actuated once fluid flow is initiated,and said signal receiver becoming actuated upon receipt of saidmeasurement data.
 14. The monitoring system of claim 1, wherein saidmeasurement data are transmitted to said signal receiver as ultra-sonicsignals.
 15. The monitoring system of claim 1, wherein said measurementdata are transmitted to said receiver in real time.
 16. The monitoringsystem of claim 1, said sensor component further comprising a thirdsensor package having a MEMS sensor, wherein said third sensor packageis in contact with the unfiltered fluid and is configured to measure atleast one member selected from the group consisting of a conductivity, apH level, and a viscosity of said unfiltered fluid.
 17. The monitoringsystem of claim 16, wherein said sensor component further includes aprocessor and said third sensor package is configured to communicate itsmeasurements to said processor.
 18. The monitoring system of claim 1,wherein the data-processing device is further configured to determinethe status of the filter element.
 19. The monitoring system of claim 18,wherein said status includes the remaining life of said filter element.20. The monitoring system of claim 1, wherein the data-processing devicereceives said data from said signal receiver in real time.
 21. Themonitoring system of claim 1, wherein at least one of the sensorpackages includes redundant MEMS sensors.
 22. The monitoring system ofclaim 1, wherein said sensor component includes a redundant sensorpackage.
 23. A filtration monitoring system comprising: a filter moduleincluding a filter element having an end cap at an end thereof, saidfilter element receiving a fluid in an unfiltered state upstream of thefilter element and producing said fluid in a filtered state downstreamof the filter element; a single-body sensor component coupled to saidend cap through a sensor port defined therethrough, said sensorcomponent having a single housing and a first micro-electromechanicalsystems (MEMS) pressure sensor and a second MEMS pressure sensordisposed within said housing, wherein said first pressure sensor isadapted to be in communication with said unfiltered fluid and saidsecond pressure sensor is adapted to be in communication with saidfiltered fluid so as to enable calculation of a differential pressurebased on respective measurements of said first and second pressuresensors; a casing having top and bottom ends and being configured tohouse therein said filter element, said end cap, and said sensorcomponent; a signal receiver coupled to said bottom end of said casing;a transmitter coupled to said sensor component, wherein said transmitteris configured to wirelessly transmit measurement data from said firstand second pressure sensors to said signal receiver; and adata-processing device configured to receive data from said signalreceiver.
 24. The monitoring system of claim 23, wherein saidmeasurement data are transmitted to said signal receiver in real time.25. The monitoring system of claim 23, further including a retainingbrace configured to be removably coupled to said end cap, said braceretaining the sensor component within said sensor port.
 26. Themonitoring system of claim 25, wherein said brace is coupled to said endcap with a connection means.
 27. The monitoring system of claim 25,wherein the sensor component is configured to be retained within saidsensor port by a plurality of overlapping braces.
 28. The monitoringsystem of claim 23, said sensor-component housing being furtherconfigured to receive a power supply and electronics thereon.
 29. Themonitoring system of claim 28, wherein said sensor-component housingfurther includes a sealing member around the periphery thereof, saidsealing member being configured to provide a fluid-tight interfacebetween said sensor-component housing and said sensor port.
 30. Themonitoring system of claim 28, wherein said power supply includes abattery.
 31. The monitoring system of claim 30, wherein said battery isrechargeable.
 32. The monitoring system of claim 23, wherein said signalreceiver includes a power supply and electronics, configured to belocked in place within a receiver housing.
 33. The monitoring system ofclaim 32, wherein said power supply includes a rechargeable battery. 34.The monitoring system of claim 23, further including a sleep-modefeature, wherein said first and second pressure sensors and said signalreceiver are configured to remain in an unactuated state in the absenceof fluid flow, said first and second pressure sensors becoming actuatedonce fluid flow is initiated, and said signal receiver becoming actuatedupon receipt of said measurement data.
 35. The monitoring system ofclaim 23, wherein the data-processing device is configured to calculatesaid differential pressure.
 36. The monitoring system of claim 23,wherein the data-processing device is further configured to determinethe status of the filter element.
 37. The monitoring system of claim 36,wherein said status includes the remaining life of said filter element.38. The monitoring system of claim 23, wherein the data-processingdevice receives said data from said signal receiver in real time.
 39. Afiltration monitoring system comprising: a filter module including afilter element having an end cap at an end thereof, said filter elementreceiving a fluid in an unfiltered state at an inlet side upstream ofthe filter element and producing said fluid in a filtered state at anoutlet side downstream of the filter element; a single-body sensorcomponent coupled to said end cap through a sensor port definedtherethrough, said sensor component having a single housing, a firstsensor package that is adapted to be in communication with saidunfiltered fluid and a second sensor package that is adapted to be incommunication with said filtered fluid, said first sensor packageincluding a first micro-electromechanical systems (MEMS) sensor, saidsecond sensor package including a second MEMS sensor, and both of thefirst and second sensor packages being disposed within said singlehousing; a casing having top and bottom ends and being configured tohouse therein said filter element, end cap, and sensor component; asignal receiver coupled to said bottom end of said casing; a transmittercoupled to said sensor component, said transmitter being configured towirelessly transmit measurement data from said first and second MEMSsensors to said signal receiver; a data-processing device configured toreceive data from said signal receiver; and a sleep-mode feature,wherein said first and second MEMS sensors and said signal receiver areconfigured to remain in an unactuated state in the absence of fluidflow, said first and second MEMS sensors becoming actuated once fluidflow is initiated, and said signal receiver becoming actuated uponreceipt of said measurement data.
 40. The monitoring system of claim 39,wherein the sensor component further includes a processor.
 41. Themonitoring system of claim 39, wherein said data-processing device isconfigured to determine the status of the filter element, calculate apressure differential across the filter element, or both.
 42. Themonitoring system of claim 39, wherein the data-processing devicereceives said data from said signal receiver in real time.